Method for installing a surface covering, and apparatus therefor

ABSTRACT

A method for installing a first surface covering element onto a surface is provided. The element has one half of a hook and loop attachment system, and the surface has the other of the hook and loop attachment system. The method may include the steps of: (i) placing the first element onto the surface so that at least some of the respective hooks and loops of the first element and surface engage; and (ii) applying a force to the first element to encourage tensioning in the loops; and (iii) securing the first element into place.

FIELD OF THE INVENTION

The invention relates to a method for installing a surface covering andapparatus for facilitating the method.

BACKGROUND OF THE INVENTION

Surface coverings such as tile, laminates, vinyl, ceramics, wood, carpetand other textiles, may be installed by attaching the coverings to thesurface being covered. Installation is primarily concerned withattachment of the element to the surface. Gaps between elements mayoccur, facilitating entry of unwanted matter such as dust or liquids.Larger gaps may be unsightly.

SUMMARY OF THE INVENTION

In accordance with a broad aspect of the present invention there isprovided a method for installing a first surface covering element and asecond surface covering element onto a surface, each of the elementshaving one half of a hook and loop attachment system, and the surfacehaving the other of the hook and loop attachment system, the methodcomprising:

(i) placing the first element onto the surface so that at least some ofthe respective hooks and loops of the first element and surface engage;

(ii) placing the second element to marginally overlap the first elementby a generally uniform amount, so that at least some of the respectivehooks and loops of the second element and surface engage; and

(iii) applying a force to the second element, adjacent the overlap, toencourage the second element to move and to become generally coplanarwith the first element and to eliminate the overlap.

The method may further comprise in step (ii), placing the second elementwith an amount of overlap that causes the loops to bias the secondelement against the first element after step (iii).

In another aspect, the amount of overlap is selected to cause the secondelement to be biased against the first element to create a seal betweenthe first and second elements that is resistant to liquid transfer.

In another aspect, the amount of overlap in step (ii) is determined by ameasurement of the maximum extension of the possible movement betweenthe second element and the surface when at least some of the respectivehooks and loops of the second element and surface engage, and theoverlap is less than or equal to such maximum extension.

In another aspect, the amount of overlap in step (ii) is a function ofthe maximum resiliency of the loops.

In another aspect, the amount of overlap in step (ii) is a function ofthe maximum length of the loops.

In another aspect, the surface is a subfloor, and the method furthercomprises, before step (i), the step of placing the subfloor onto afloor, without attaching the subfloor to the floor.

In another aspect, the force is applied by hand.

In another aspect, the force is applied by a blunt instrument.

In another aspect, the force is applied progressively from one area ofoverlap to another area of overlap.

In another aspect, in step (ii) the second element is placed in astaggered relationship relative to the first element.

In another aspect, the method further comprising the step of:

(iv) placing a third element to marginally overlap both the first andsecond elements along adjacent edges by generally uniform amounts, sothat at least some of the respective hooks and loops of the thirdelement and surface engage; and

(v) applying a force to the third element, adjacent the overlap, toencourage the third element to move and to become coplanar with thefirst and second elements and to eliminate the overlaps.

In another aspect, the method further comprising the step of:

(iv) repeating all previous steps for a third element in conjunctionwith at least one of the first and second elements.

In another aspect, the first element is rigid.

In another aspect, the first element is made of one of vinyl, wood,linoleum, plastic, ceramic and rigid backed carpet.

In another aspect, the method further comprising, after step (i),positioning a template relative to the first element to cause the secondelement to overlap the first element by a predetermined amount; and,after step (ii), removing the template.

In another aspect, the first element also moves to tension the loops.

In another embodiment there is provided a decorative floor coveringinstallation comprising:

a first surface covering element;

a second floor covering element;

a surface for receiving the first and second elements, each of theelements having one half of a hook and loop attachment system, and thesurface having the other of the hook and loop attachment system, thefirst and second elements being attached to the surface by the hooks andloops, and the first and second elements being biased against oneanother.

In another aspect, at least some loops are approaching maximum extensionand movement of at least one of the elements away from the other islimited.

In another aspect, at least some loops are approaching maximum extensionso that the first element is biased against the second element to form aliquid resistant seal.

In another aspect, the surface is a free floating subfloor.

In another aspect, wherein the first element is rigid.

In another aspect, wherein at least some loops are extended by apredetermined amount.

In another aspect, the predetermined amount is at least twenty-fivepercent of a maximum extension of the loops.

In another aspect, the first element is flexible and resists folding.

In another aspect, the first element is made of one of vinyl, wood,linoleum, plastic, ceramic and rigid backed carpet

In a further embodiment there is provided a method for making a floorcovering module having a covering element with at least one sidesubstantially covered in one of hooks and loops of a hook and loopattachment system, and a sheet substantially covered the other of hooksand loops, the method comprising the steps of:

(i) bending the sheet;

(ii) placing the covering element onto the sheet to permit at least someof the hooks to engage at least some of the loops; and

(iii) flattening the combined sheet and covering element for placementonto a surface.

In another aspect, the sheet is bent to present a convex surface forattachment to the covering element.

In another aspect, the sheet is bent to present a generally helicalsurface for attachment of the covering element.

In another aspect, the covering element is placed onto the sheet tooverlap along at least one edge.

In a further alternative embodiment there is provided a planar surfacecomprising a subfloor substantially covered with loops and at least twodecorative covering elements having complementary loops for attachmentto hooks, in which at least some of the loops of at least one of thedecorative covering elements are in tension pulling that element in toabutment with the other element.

In a yet further embodiment there is provided a method for installing afirst surface covering element onto a surface, wherein the element hasone half of a hook and loop attachment system, and the surface has theother of the hook and loop attachment system, the method comprising thesteps of: (i) placing the first element onto the surface so that atleast some of the respective hooks and loops of the first element andsurface engage; (ii) applying a force to the first element in adirection generally parallel to the surface, to encourage tensioning inthe loops; and (iii) securing the first element into place.

Other and further advantages and features of the invention will beapparent to those skilled in the art from the following detaileddescription of embodiments thereof, taken in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE FIGURES

The present invention will be further understood from the followingdetailed description of embodiments of the invention, with reference tothe drawings in which:

FIG. 1 illustrates in isometric view, a partially installed decorativecovering over a field of hooks;

FIG. 2 is a side view of decorative elements installed onto a field ofhooks;

FIG. 3 shows an alternative hook sheet for providing a field of hooks;

FIG. 4 is a partial side view of a decorative element and correspondinghooked surface prior to attachment;

FIG. 5 illustrates the decorative element and hooked surface of FIG. 4engaged;

FIG. 6 is an isometric view of FIG. 5;

FIG. 7 illustrates a decorative element overlapping an adjacentdecorative element prior to installation;

FIG. 7 a illustrates a loop in various degrees of extension;

FIG. 7 b is a top view of FIG. 7;

FIG. 8 illustrates the decorative element of FIG. 7 installed;

FIG. 9 is an isometric view of a template;

FIG. 10 is an isometric view of an alternative embodiment of a template;

FIG. 11 is a side view of the template of FIG. 9 in use;

FIG. 12 illustrates installation of a decorative element using analternative template;

FIG. 12 a illustrates the installation of decorative elements having acomplimentary tongue and groove;

FIG. 13 illustrates a method of installing decorative elements using thetemplate of FIG. 9;

FIG. 14 illustrates the installation of decorative elements in additionto those of FIG. 13;

FIG. 15 illustrates the installation of decorative elements employingthe template of FIG. 10;

FIG. 16 illustrates the installation of decorative elements in additionto those illustrated in FIG. 15;

FIG. 17 illustrates the installation of decorative elements employingboth the template of FIG. 9 and the template of FIG. 10;

FIG. 18 illustrates the installation of different developments having anirregular configuration;

FIG. 19 illustrates a bendable hook sheet;

FIG. 20 illustrates a bendable decorative element;

FIG. 21 illustrates the attachment of the hook sheet of FIG. 19 and thedecorative element of FIG. 20;

FIG. 22 illustrates the module of FIG. 21 unbended;

FIG. 23 illustrates an installation of multiple modules of FIG. 22;

FIG. 24 illustrates a blunt instrument; and

FIG. 25 illustrates a spreader assembly.

DETAILED DESCRIPTION OF THE INVENTION

Similar references are used in different figures to denote similarcomponents. Proportions and positioning of illustrated elements may beexaggerated or distorted in order to better illustrate the methods andapparatus.

Releasable attachment systems have been used to conveniently installdecorative floor coverings. In particular, complimentary hook and loopattachment systems, such as those disclosed and in prior patents (andapplications) including U.S. Pat. Nos. 6,306,477; 6,298,624; 6,802,167;7,096,632; and application Ser. Nos. 10/013,688; 10/543,905; 10/543,904;10/543,902; 10/543,906; 10/879,149; 10/543,901; and 10/543,903, all ofwhich are herein incorporated by reference.

In general, a field of hooks (or loops) may be provided on a surface tobe covered. A decorative covering may be provided having a side coveredwith loops (or hooks, as the case may be) for engaging the complimentaryhooks (or loops) of the surface. This arrangement has the advantage thatthe decorative coverings may be easily repositioned during installation,and after installation, one or more decorative coverings may be removedand replaced to address wear and tear, or to change the appearance ofthe surface that is covered. The present disclosure provides methods andtools for encouraging the installed decorative coverings to fit moreclosely with one another. This is achieved by biasing or tensioning thehook and loop attachment as described herein. This may reduce theoccurrence of unsightly gaps between the decorative coverings, and, tothe extent that adjacent decorative coverings abut one another, suchinstallation may also inhibit the passage of foreign elements such asdust, and possibly liquids, between the decorative coverings.

FIG. 1 illustrates a field of hooks 20 for receiving a decorativecovering. The field of hooks may be provided by an installed anchorsheet sub-floor (as disclosed in the patents and applications listedabove) or by attaching a hook tape to a surface or in some other knownmanner. Field of hooks 20 may be free floating (if installed on a floor,for example), or it might be glued, screwed, nailed, or otherwiseattached to the surface (particularly if used on non-horizontal surfacessuch as walls and ceilings).

Surface covering elements 22, such as vinyl planks, may be provided withloops 24 (as illustrated in FIG. 2) for engagement with the hooks of thefield of hooks 20. Any other decorative covering may be used, such asdecorative coverings made of vinyl (including luxury vinyl tile), wood(including wood products, laminates and composites), linoleum, plastic,ceramic, and generally rigid textiles, such as rigid backed carpet.Preferably, the decorative coverings used resist folding. Anycombination of these coverings may also be used. It is preferred thatthe decorative covering used has a degree of rigidity that inhibits itfrom significantly deforming when a lateral force is applied to it andthe loops (or hooks) of the decorative covering are at least partiallyengaged. It should be noted that the decorative covering may instead beprovided with hooks, and loops may be provided to cover the surface.

Decorative elements may also have different or complimentary geometricshapes. The shapes may also be irregular or non-uniform so long asadjacent decorative elements may be installed according to the methoddescribed herein. An example of irregular decorative elements isillustrated in FIG. 18, irregular patterns of two or more decorativeelements each having different but complimentary shapes may also beemployed either in a pattern, or in a unique arrangement.

FIG. 2 illustrates an embodiment having one or more hooked sheets 26that are used to provide a field of hooks for attachment of planks 22.Hooked sheets 26 may optionally be provided with a resilient layer or acushion 28 to improve the comfort of the decorative covering when usedor walked upon. As noted, many of the figures have their dimensionsexaggerated in order to illustrate the new method, installation andtools. Typically, the loops 24 will extend approximately.

For example, a typical hook sheet might be between a sixteenth of aninch and three quarters of an inch thick, and a typical decorativeelement may have similar dimensions. However, thinner and thickerdecorative elements and hook sheets may be employed. When a hook sheetwith integral stems is used, the stems may be one millimeter high and0.55 millimeter in diameter. The hooks (and sheet) may be made ofpolypropylene. The ratio of stem height to diameter is preferably about2:1, and may be as great as 10:1. The stem diameter may be in thegeneral range of 0.3 to about 0.9 millimeters. Stem diameters of assmall as 0.1 millimeter may be acceptable.

Decorative elements, such as luxury vinyl tile that are typically usedwithout hook and loop attachment may be converted simply by adding hooksand loops, as appropriate. Alternatively, decorative covering elementsmay be specifically manufactured to take advantage of the hook and loopattachment systems. For instance, such decorative coverings may bemanufactured to have less rigidity because the hook surface or hooksheets will also contribute to the overall rigidity of the floorcovering.

FIG. 3 illustrates a field of hooks provided by hook sheets 26 (whichmay include hooked attachment devices 30) as disclosed in U.S. Pat. No.7,096,632.

FIG. 4 shows a decorative covering 22 prior to installation onto a fieldof hooks 20. Field of hooks 20 is illustrated having integral hooks 32.Hooks 32 may be “mushroom-shaped”. Non-integral hooks, such as includedwith hook tape, and non-mushroom-shaped hooks, may be used. In fact, anyelement that conveniently engages a loop surface (or velvet-typefastener) may be employed.

FIG. 5 shows the decorative covering element 22 having at least some ofloops 24 in engagement with hooks 32. As decorative element 22 is movedtowards hook sheet 26 in a generally lateral direction “A”, one or moreloops 24 engage or “lasso” one or more hooks 32. In this arrangementthere may be play between decorative element 22 and field of hooks 20 ina direction generally perpendicular to direction “A”. There is generallylittle or no play if removal of decorative element 22 is attempted in adirection generally opposite to direction “A”, because some loops 24 arenow engaged with hooks 32. However, decorative element 22 mayconveniently be removed from field of hooks 20 by prying or bending anedge of the element and peeling it away from the field of hooks 20. Inthis manner one or more decorative elements 22 may be repaired and/orreplaced. This first decorative element 22 is preferably installed sothat loops 24 have minimal or no tension in a direction generallyperpendicular to “A” (though it may have such tension).

FIG. 6 illustrates a plank 22 attached to a hook sheet 26 in the mannerof FIG. 5. Plank 22 may move in a plane generally parallel to hookedsheet 26 due to at least one of: (a) play in the length of loops 24 andresiliency in loops 24. Depending on the material used for hooks 32,there may be additional play in the hooks themselves. Similarly, thegeometry of the stem 34 and head 36 of hook 32 may also contribute tothe degree of play of plank 22 (or other decorative elements) relativeto hooked sheets 26. Such play may be undesirable, particularly whendecorative elements having clearly defined edges are used. For example,when multiple planks 22 (as seen for example in FIG. 1) are laid ontothe field of hooks 20, any gaps between planks 22 may be noticeable dueto the regular geometric edges of each plank 22. Furthermore, even aminimal degree of play provided by loops 24 (and to a lesser extent, ifat all, hooks 32) may permit undesirable foreign matter to enter anysuch gap.

FIG. 7 illustrates another step in the installation of decorativeelements onto a field of hooks. Once a decorative element 22 has beeninstalled onto one or more hooked sheets 26 (decorative element 22 isillustrated in FIG. 7 as being attached to at least 2 hooked sheets 26),a second complimentary decorative element 38 may be installed.

Decorative element 38 may be identical to decorative element 22, but itneed not be. For example, decorative element 22 may be a wooden or vinylfloor plank, whereas decorative element 38 may be made of ceramic orsome other material. It is preferable that corresponding edges 22 a and38 a of decorative elements 22 and 38 are generally congruent to oneanother (as shown in FIGS. 1 and 7). The relative thicknesses 22 b and38 b of the decorative elements may be the same, or they may bedifferent, depending upon the intended use or visual effect desired.

Decorative element 38 may be placed upon one or more anchor sheets 26 sothat at least some loops of decorative element 38 are caught or retainedby one or more hooks 32. Unlike the installation of decorative element22, decorative element 38 is installed so that it overlaps decorativeelement 22, preferably along an edge thereof. The amount of overlap “B”is preferably similar to a length “L” of a loop 24.

FIG. 7 a presents an isolated view of a loop 24. FIG. 7 a(i) shows loop24 unextended. FIG. 7 a(ii) illustrates that loop 24 may be extended bydistance “M”, for example, when loop 24 engages a hook (not shown) andat least one of the loop 24 and the hook is moved. Any resiliency inloop 24 to return to its original shape of FIG. 7 a(i) will cause aforce to be exerted upon the hook. If the loop is not resilient, thenthe loop, when extended as shown in FIG. 7 a(ii), will inhibit furthermovement of an attached hook. FIG. 7 a(iii) illustrates a loop that canresiliently stretch by distance “N”. In this position, the loop mayexert additional force on an attached hook. In all of the sub-figures ofFIG. 7 a, loop 24 is shown extended generally perpendicularly tosubstrate 25. In practice, loop 24 will typically be extended at anangle relative to substrate 25 as an attached decorative element 38 ismoved as it is installed.

Overlap “B” may be calculated based upon the length and resilience ofloop 24 and the desired force of abutment between decorative elements 38and 22. For example, overlap “B” may be similar to distance “L”,particularly if many loops 24 are compressed or bent adjacent to thesubstrate 25 to which loop 24 is attached. An overlap “B” in the rangeof L+M, or L+M+N may also be selected, depending upon the resiliency ofloops 24 and the requirements of the installation (e.g., closelyabutting decorative elements).

Accordingly, to the extent that loops 24 (or hooks 32) also haveelasticity or resiliency, the overlap “B” may be greater. In anembodiment, overlap “B” may be between about one millimetre and thirtymillimetres and might also be in the range of two millimetres to tenmillimeters. An overlap “B” of about 2 to 3 millimetres has been foundto be effective. In the present example, overlap “B” is about 2millimetres.

The amount of overlap “B” may be determined by a measurement of themaximum extension of the possible movement between the decorativeelement 38 and field of hooks 20, when at least some of the respectivehooks 32 and loops 24 of decorative element 38 and field of hooks 20engage. For example, this may be done by placing (in direction “A”)decorative element 38 upon a field of hooks 20 and then applying aforce, for example, in direction “C”. The maximum relative displacementof decorative element 38 may be used as overlap “B”. Overlap “B” ispreferably less than or equal to such maximum extent of movement.

For example, in an embodiment, decorative element 38 can move by twomillimeters when at least partially attached and generally parallel tofield of hooks 20. Accordingly, overlap “B” is preferably about twomillimeters or less. The closer that overlap “B” is to the maximumrelative movement, the greater the likelihood that decorative element 38will exert force against decorative element 22 once installed. If loops24 are not resilient, overlap “B” will typically be less and a forceexerted by decorative element 38 upon decorative element 22 may be less.In this example, loops are manufactured by stitching polyester yarn (toform the loops) through a polypropylene layer using a malimo process.Such loops are manufactured by Scott & Fyfe in Scotland under partnumber 40/film. Suitable loops made by other manufactures and with othermaterials may also be suitable. For example, fleece or “fluffy”materials may be suitable. The hooks are mushroom shaped and may havethe following approximate dimensions: 0.5 mm diameter; 0.6 mm length;and 0.9 mm head.

Even if a force is not exerted, an overlap “B” may be used to at leastreduce the amount of play in decorative element 38 relative to field ofhooks 20.

To install decorative element 38, a force is applied to decorative 38.Force is applied in the region of the overlap to (i) cause decorativeelement 38 to become generally co-planer with decorative element 22, and(ii) to enable at least one loop 24 that is free to engage a hook 32.For decorative elements 38 made of more rigid materials, the forceapplied may be in the general direction “C”. The force is applied ingeneral direction “C” until overlap “B” is reduced or eliminated. Aforce may then be applied in the general direction “A”. It must beemphasized that the particular direction that decorative element 38 ismoved need not be precise, as long as the overlap area “B” iseliminated, and decorative element 38 is permitted to become somewhatco-planer with decorative element 32.

For less rigid decorative elements, a force in a combined direction A+Cmay be applied, where the particular force component A or C may bedifferent, or varied. When relatively resilient luxury vinyl tile isused for decorative element 38, a quick blunt force applied in thegeneral direction “A” to the overlap area “B” can serve to quickly placedecorative element 38 into the desired alignment (as shown in FIG. 8).This may work with other materials as well.

The amount of force and the manner in which it is applied may varydepending on the material used for decorative element 38. For example,if a resilient material is used, then a blunt instrument such as ahammer or a rigid brick-like structure, or some other suitable element,may be used without damaging the decorative coverings 38 and 22. Paddingmay be applied to any tool (or hand) used to apply the force in order toreduce damage to the decorative element. Similarly, protective paddingmay be applied onto any area of a decorative covering that receives aforce. For some installations, it may be possible to simply apply theforce to decorative element 38 by hand. However, this may not be asefficient as using a tool. On the other hand, for particularly brittleor delicate floor coverings 38, hands or tools gently applied may berequired to protect the covering.

Any force applied to decorative covering 38 may ideally be applied alongthe entire overlap area at once. Alternatively, force may be applied attwo or more regions of the overlap area, either simultaneously orsequentially. For example, force may be applied at one end of theoverlap area (see FIG. 8) and progressing to another end of the overlaparea to progressively cause decorative element 38 to align withdecorative element 22. A roller could be used to progressively impartsuch a force along the interface between decorative element 38 and 22

As a force is applied to decorative element 38 to move it, loops 24 arecaused to slide around respective hooks 32 and at least some of theloops become taut. Thus a tensioning or biasing force is created,encouraging the decorative element 38 to abut decorative element 22.This may reduce the extent of movement of decorative element 38 ingeneral, and in particular, it may serve to reduce the extent ofmovement of decorative element 38 within the plane of decorative element38. To the extent that loops 24 (or hooks 32) are resilient, applyingadditional force may stretch the loops 24 and/or hooks 32 to furtherinhibit movement of decorative element 38. This arrangement may alsoinhibit unintentional removal of the decorative elements 22 and 38.

If there is minimal or no resiliency in loops 24 (or hooks 32), thenwhen decorative element 38 is brought into alignment with decorativeelement 22, the ability of decorative element 38 to move relative tofield of hooks 20 may be reduced as compared to a decorative elementinstalled in the manner of FIGS. 4, 5 and 6. In many embodiments, most,if not all, of the play that permits decorative element 38 to moverelative to decorative element 22 in order to eliminate the overlap, isprovided by loops 24.

If overlap “B” is made large relative to the length “L” of loops 24, orif it is made large relative to the resilient extent of loops 24, thenadditional energy may be stored in the loops 24 that initially engagehooks 32 when decorative element 38 is first placed upon field of hooks20. This additional energy is stored when decorative element 38 is madeco-planer with decorative element 22. As overlapped decorative element38 is moved into place, loops 24 become taught around correspondinghooks 32. (If resilient loops are used then, loops 24 elasticallystretch as additional force is applied to decorative element 38.) Whendecorative element 38 is aligned with decorative element 22, loops 24that have been elongated and/or stretched, exert a force to encouragedecorative element 38 towards decorative element 22 in a directiongenerally opposite to direction “C”. This may encourage decorativeelement 38 to abut decorative element 22. This abutment may reduce anyunsightly gaps between decorative element 38 and 22. It may also reducethe ability for foreign and unwanted matter to pass between decorativeelements 38 and 22. When sufficiently resilient loops 24 (and/or hooks32) are used, the force exerted by decorative element 38 upon decorativeelement 22 may be sufficient to make the interface between thedecorative elements resistant, or possibly even impermeable, to aliquid.

If decorative element 38 is not adequately aligned relative todecorative element 22, then a gap may still exist. It has been foundthat as additional decorative elements are added adjacent to theinstalled decorative elements, any gaps between previously installeddecorative elements may be reduced or eliminated.

The described installation has the further advantage that, as theinstalled decorative elements (and other components) expand and contractdue to environmental conditions, the play provided by the combined hook32 and 24 arrangement, may accommodate some of such expansion andcontraction, and may reduce the likelihood of the decorative elements toform gaps, or to cup or buckle.

Additional accommodation for excess stress within the components of thedecorative covering and field of hooks may be obtained by use of hookedsheets 26 that are permitted to free float over, or have minimalattachment to, a surface such as a floor. For example, a gap “G” may beprovided when hooked sheets 26 are laid upon a surface. Gap “G” may beas small as a fraction of a millimetre and may be as large as onecentimetre or more, depending upon the nature of the surface element 22and the intended use for the covering. In an embodiment, a gap “G” ofabout 2 millimetres may be used. Gap “G” may permit movement of one ormore hook sheets 26 as decorative element 38 is being installed. Forexample, if overlap area “B” is too large, and there is not enough playand/or resiliency within hooks 32 or loops 24 to permit installation ofdecorative element 38, then hooked sheets 26 may move to reduce or closegap “G” to permit installation of decorative element 38. Similarly,expansion and contraction of the various elements described due toenvironmental or other factors may be accommodated by gaps “G”. This mayserve to reduce cupping, bending, and other deformations in the surfacemade up of decorative elements such as decorative elements 22 and 38.Gaps “G” may affect the calculation of the preferred overlap “B”,because the gaps may permit additional movement of portions of hookedsurface 20, particularly when a decorative element 38 spans a gap “G”.

Alternative hook sheets 40 may be employed to permit movement of hooksheets relative to one another. Such hook sheets may have overlappingexpansion areas about portions 42 and 44. Hook sheets that include thisconfiguration are illustrated in FIG. 3 (but the sheets illustrated inFIG. 3 have additional elements including attachment devices 30, thatmay not be necessary).

As noted above, the various components described, when installed, tendto be nearly flush with one another. Any gaps or spaces shown in thefigures are exaggerated for illustration and ease of explanation.Similarly, the field of hooks 20 and hook sheets 26 forming a field ofhooks 20 are sometimes illustrated in the figures with hooks missing inan area or with hooks missing about the edges or perimeter. This is donefor ease of illustration or may be done for ease of manufacture.However, hooks may be included over the entire surface, or strategicallyplaced upon select portions of a surface to be covered to enabledecorative elements to be installed in a manner described herein.

FIG. 8 illustrates decorative element 38 installed according to themethod above. Note that some loops 46 may be extended or stretched abouta portion, or all, of hooks 36. Such stressing or tensioning of loopsmay cause decorative element 38 and 22 to become biased against oneanother. Nevertheless, one or more of decorative elements 22 and 38 maybe removed, for example, by prying so that such element may be replacedor repaired. This may sometimes be done by hand, but may be convenientlydone by inserting a narrow tool, such as a spatula or putty knife,between decorative element 38 and 22, and prying or peeling the desireddecorative element away.

FIG. 8 also illustrates how gaps “G” may change in size after decorativeelement 38 is installed. For example, gap “G” between sheets 40 may belarger, and gap “G” between sheets 40 and 26 may become smaller.

In the foregoing embodiments an overlap has been used to permit theengagement and tensioning of connected hooks and loops to encouragedecorative element 38 to be retained by surface 20, and to encourageabutment of decorative element 38 against decorative element 22. Inanother embodiment, a fixed feature (not shown) such as a piece of woodnailed or glued to a surface may be used instead of decorative element22 (at least for the installation of a first decorative element 38, orrow of decorative elements 38). In this embodiment, decorative element38 is overlapped with the fixed feature, and installed as describedabove.

In a further alternative embodiment, decorative element 38 is placedupon surface 20 in general direction “A”. A force generally parallel tosurface 20 may be applied to decorative element 38. This force may causedecorative element 38 to become displaced, and loops 24 (and possiblyhooks 32) to be elongated or stretched in the manner described herein.Once decorative element 38 is displaced by a desired amount, it may beheld generally in place by placing decorative element 24 in abuttingrelationship to it. Any resilience in loops 24 (or hooks 32) may causemarginal displacement of decorative element 24. In this embodiment, asimilar abutting relationship is achieved to that described for whendecorative covering 38 is installed by overlapping it. Decorativeelement 38 may alternatively be held in place, once moved, by somethingother than decorative element 22. In this embodiment, decorative element38 may be moved by hand or by employing a tool having a slip resistantsurface.

FIG. 9 illustrates a template that may be used to assist in facilitatingalignment between decorative element 38 and 22 so that there is apreferred or predetermined overlap “B”. The various dimensions oftemplate 48 may be varied as needed. For example, FIG. 10 illustrates anelongate template 50, which may have a similar cross section to template48, but that has a greater length to accommodate different installationpatterns (described later) or different sized decorative elements.Handles 52 may also be included.

Template 48 is illustrated having a straight edge. This is done so thatit conforms to an edge such as edge 22 a of a decorative element 22. Ifdecorative element 22 has a curved edge, or an irregular edge, thentemplate 48 may be configured accordingly.

FIGS. 11, 12 and 12 a illustrate the use of various templates andmethods used to install decorative elements. For ease of illustration,these figures do not show the hook and loops in detail. As noted, thehook and loop arrangement may be reversed.

FIG. 11 illustrates use of template 48 to encourage proper placement ofdecorative element 38 relative to decorative element 22. A leg or otherprotrusions 54 provides a stop for template 48 to align it relative todecorative element 22. A rebate 56 is configured to provide apredetermined amount of overlap for decorative element 38 relative todecorative element 22. Once decorative element 38 is positioned,template 48 may be removed. Template 48 is preferably removed by slidingit along edge 22 a. If it is not possible to slide template 48, then itmay be carefully lifted while holding attached portions of decorativeelement 38 in place. Decorative element 38 may then be installed in amanner described above.

FIG. 12 illustrates an alternative template 58. Template 58 is held inplace by hook and loop, or some other means, to the surface such as afloor 60. Template 58 is placed a distance “D” from decorative element22 to position decorative element 38 so that it overlaps by amount “B”when it is abutted against template 58. Decorative element 38 may thenbe installed in the manner described above. Template 58 may also beprovided with a standoff (not shown). The standoff may be in the natureof an arm for abutting against edge 22 a of decorative element 22. Thestandoff may permit template 58 to be held in place manually, withoutthe need for attachment to a surface such as floor 60.

In an alternative embodiment, a template congruent to but smaller thanthe decorative element 38 may be placed on the surface 20. Decorativeelements 24 may then be placed adjacent the perimeter of the template.The template may then be removed to reveal an exposed area of surface 20that is marginally smaller than decorative element 38. Decorativeelement 38 may then be placed within the exposed area with one or moreedges overlapping a respective decorative element 24. Each overlap maythen be removed employing the method described above.

FIG. 12 a illustrates the installation of decorative elements 62 and 64having cooperating tongues and grooves. Decorative element 64 having anexposed tongue or groove may be installed in the manner described above.Decorative element 62 having the other of a tongue and a groove may beinstalled using a sheet 66 that has at least one surface that does notengage hooks 32. Such surface is placed against hooks 32. A thickness ofsheet 66 may correspond to a distance between decorative element 64 andfield of hooks 20.

Decorative element 62 is installed by first placing sheet 66 upon fieldof hooks 20. Decorative element 62 may then be slid into position byapplying a force in the general direction “H”. Sheet 66 is then removed.While this installation method may not provide significant biasing ofdecorative element 62 against decorative element 64, it enables thepositioning of the tongue within the groove to inhibit passage offoreign matter, and to reduce the occurrence of gaps between decorativeelements.

FIGS. 13 to 17 illustrate an example of how decorative elements such asplanks 22 and 38 may be installed. It is emphasized that this is but anexample and many other variations may be employed to install decorativeelements according to the method described herein. Furthermore, theparticular demands of the installation and the properties of thedecorative elements and field of hooks may require different steps to betaken and a different orientation of elements.

FIG. 13 illustrates a number of decorative elements 22 placed upon afield of hooks 20. It is not necessary for such decorative elements tobe installed in a manner described above. Such decorative elements maybe placed upon the field of hooks, in a staggered relationship, withoutoverlap. Subsequent installation of additional decorative elements mayserve to exert a force on the installed decorative elements shown inFIG. 13 (alternatively, one large decorative element could be installedinstead of multiple decorative elements 22). Once decorative elements 22are installed, templates 48 may be placed along an end of eachdecorative element 22.

FIG. 14 illustrates a number of decorative elements 38 placed intoposition and oriented using template 48. Decorative elements 38 may bestaggered as shown. Templates 48 are shown in plan on the surface ofelement 22, and can be seen in the side view of FIG. 11. Templates 48may be removed in the manner described above, and planks 38 installedaccordingly.

FIG. 15 illustrates use of an elongate template 50. Elongate template 50is placed in a similar manner to template 48. Template 50 is placed onthe top row of elements 22 (labeled as 23 to highlight their location),and in this illustration the row consists of parts of at least fourdecorative elements. Template 50 permits an efficient installation ofmultiple or oversized decorative elements.

FIG. 16 illustrates additional decorative elements 38 installed andoriented by template 50. Template 50 may be removed by sliding it alongdecorative elements 38, or lifted, until it is free. Decorative elements38 may be installed as described above. By installing multipledecorative elements at a time as illustrated in FIGS. 13 to 17, adesired fit is encouraged between all decorative elements, without theneed to install each and every decorative element according to themethod separately. Of course, it is possible to simply install eachdecorative covering independently according to the disclosed method.

FIG. 17 illustrates the use of templates 48 and 50 in conjunction witheach other. Some decorative elements 38 will be provided with an overlapwith two adjacent decorative elements 22. This encourages the reductionin play, and may cause tension, in loops 24 (and/or hooks 32) in atleast two general directions. This serves to encourage other decorativecoverings that have been already installed (such as the decorativecoverings of FIG. 13) to be encouraged into abutting relationship toreduce the size of any gaps. This arrangement may also cause suchdecorative elements to become biased against one another along at leastone or more of their respective edges.

As noted, FIG. 18 illustrates one or more irregularly shaped decorativeelements 68 that may be installed onto a field of hooks 20 using thedisclosed method.

Decorative elements may also be attached to a field of hooksindependently in order to form modules that may be installed to cover asurface. FIG. 19 illustrates a hook sheet 70 for receiving a decorativeelement. Hook sheet 70 includes hooks 32 across some or all of itssurface. A resilient cushion 72 may also be included, but may also beexcluded. Hook sheet 70 is somewhat flexible to permit attachment to adecorative covering in the manner described below. Loops mayalternatively be provided by sheet 70 and hook may be located ondecorative elements to be attached.

FIG. 20 illustrates a decorative element 74 which may be made of vinylor other somewhat flexible material. Decorative element 74 may alsoinclude textiles such as carpet. Decorative element 74 may be providedwith a surface at least partially covered with loops 24.

As illustrated in FIG. 21, hook sheets 70 may be bent to present agenerally convex hooked surface (it may alternatively be bent to presenta generally concave hooked surface). Hook sheet 70 is then maintained ina bent position, and decorative covering element 74 is placed thereon.At least some hooks 32 and loops 24 engage. (Alternatively, hook sheet70 may be bent in some other way, such as to form a somewhat helicalsurface. Covering element 74 may be similarly attached.)

As shown in FIG. 22, the now combined hook sheet 70 and decorativeelement 74 are returned to a generally plainer configuration forplacement on a surface. The bending of hook sheet 70 prior to attachmentof the decorative element causes some hooks and loops to engage in thebent position. When the combined module is flattened, at least somehooks move relative to the attached loops, and any play in the loops maybe reduced. This reduction in play may serve to improve the attachmentbetween decorative element 74 and hook sheet 70 as compared to merelyplacing a generally planer decorative element 74 upon a hook sheet 70.

Decorative covering 74 and hook sheet 70 are preferably offset along atleast one edge. This permits the combined module formed by thedecorative covering and the hook sheet to be attached to like decorativecoverings and hook sheets as shown in FIG. 23. Such modules 76 may beplaced adjacent one another in overlapping relationship. Module 76 mayalso be assembled by employing the method described above by overlappingadjacent decorative elements 76. As shown in dashed lines in FIG. 23,decorative elements 74 and hook sheets 76 are oriented relative to oneanother so that a gap “J” is formed between installed hook sheets 70.Gap “J” may be similar in size to a preferred overlap “B”. This mayfacilitate the method described above to be carried out by providingroom for the hook sheets 76 to move. Gap “J” also permits expansion andcontraction of elements of module 76. The installation may also havelittle or no gap “J”.

While it is preferred that decorative element 74 is somewhat flexible. Amore rigid decorative element, for example, made of wood, may be usedwith some benefit. When a stiff decorative element is used, bending ofhook sheet 70 should be minimal to encourage at least a few hooks andloops to engage. Once hook sheet 70 is flattened, some tensioning ofpreviously engaged hooks and loops may provide improved securement ofthe rigid decorative element to the hook sheet.

FIG. 24 illustrates one example of a blunt instrument 80 that may beused to encourage the movement of decorative element 38 relative todecorative element 22. Blunt instrument 80 is preferably made of arelatively heavy material such as a metal. Blunt instrument 80 mayinclude a cushion 82, made of a deformable substance such as rubber sothat the decorative elements are not damaged when they come into contactwith blunt instrument 80. Blunt instrument 80 may also include a handle84. Blunt instrument 80 may be used in the manner described above. Forexample, it may be applied generally in direction “A” by applying forceto overlap “B”. Force may also be applied to some extent in direction“C” to encourage movement of decorative element 38.

FIG. 25 illustrates an alternative tool that may be used to encouragethe movement of decorative element 38 relative to decorative element 22.Spreader 86 includes two grips 92, each of which is placed on therespective decorative elements 22 and 38. Grips 92 may be made of rubberor other suitable material that resists slipping or sliding on a surfaceof the decorative elements. Grips 92 are joined by handle portions 86 aand 86 b. Portions 86 a and 86 b slidably engage one another. Portion 86a may be provided with a spring loaded lever 88 pivotally mountedthereto. An end of lever 88 may include a spring 90 mounted thereto. Theother end of spring 90 may be mounted to portion 86 a. The spring end oflever 88 also engages portion 86 so that pivoting movement of lever 88may cause grips 92 to move relative to each other. Accordingly, whenlever 88 is squeezed toward portion 86 a, grips 92 move apart. Thiscauses decorative elements 38 and 22 to move relative to one another andto ultimately become co-planer, as described above. When the spreader 86is lifted away from the decorative elements, the spring 90 causes thegrips 92 to return to a position where they are closer to one another.

While the foregoing embodiments of the invention have been described insome detail for purposes of clarity and understanding, it will beappreciated by one skilled in the art, that numerous modifications,variations, and adaptations may be made to the particular embodiments ofthe invention described above without departing from the scope of theinvention, which is defined in the following claims.

1. A method for installing a first surface covering element and a secondsurface covering element onto a surface, each of the elements having onehalf of a hook and loop attachment system, and the surface having theother of the hook and loop attachment system, the method comprising: (i)placing the first element onto the surface so that at least some of therespective hooks and loops of the first element and surface engage; (ii)placing the second element to marginally overlap the first element by agenerally uniform amount, so that at least some of the respective hooksand loops of the second element and surface engage; and (iii) applying aforce to the second element, adjacent the overlap, to encourage thesecond element to move and to become generally coplanar with the firstelement and to eliminate the overlap.
 2. The method of claim 1, furthercomprising in step (ii), placing the second element with an amount ofoverlap that causes the loops to bias the second element against thefirst element after step (iii).
 3. The method of claim 2, wherein theamount of overlap is selected to cause the second element to be biasedagainst the first element to create a seal between the first and secondelements that is resistant to liquid transfer.
 4. The method of claim 3,wherein the amount of overlap in step (ii) is determined by ameasurement of the maximum extension of the possible movement betweenthe second element and the surface when at least some of the respectivehooks and loops of the second element and surface engage, and theoverlap is less than or equal to such maximum extension.
 5. The methodof claim 3, wherein the amount of overlap in step (ii) is a function ofthe maximum resiliency of the loops.
 6. The method of claim 3, whereinthe amount of overlap in step (ii) is a function of the maximum lengthof the loops.
 7. The method of claim 1, wherein the surface is asubfloor, and the method further comprises, before step (i), the step ofplacing the subfloor onto a floor, without attaching the subfloor to thefloor.
 8. (canceled)
 9. (canceled)
 10. The method of claim 1, whereinthe force is applied progressively from one area of overlap to anotherarea of overlap.
 11. The method of claim 1, wherein in step (ii) thesecond element is placed in a staggered relationship relative to thefirst element.
 12. The method of claim 11, further comprising the stepof: (iv) placing a third element to marginally overlap both the firstand second elements along adjacent edges by generally uniform amounts,so that at least some of the respective hooks and loops of the thirdelement and surface engage; and (v) applying a force to the thirdelement, adjacent the overlap, to encourage the third element to moveand to become coplanar with the first and second elements and toeliminate the overlaps.
 13. The method of claim 1, further comprisingthe step of: (iv) repeating all previous steps for a third element inconjunction with at least one of the first and second elements.
 14. Themethod of claim 1, wherein the first element is rigid.
 15. The method ofclaim 1, wherein the first element is made of one of vinyl, wood,linoleum, plastic, ceramic and rigid backed carpet.
 16. The method ofclaim 1, further comprising, after step (i), positioning a templaterelative to the first element to cause the second element to overlap thefirst element by a predetermined amount; and, after step (ii), removingthe template.
 17. The method of claim 1, in which the first element alsomoves to tension the loops.
 18. A decorative floor covering installationcomprising: a first surface covering element; a second floor coveringelement; a surface for receiving the first and second elements, each ofthe elements having one half of a hook and loop attachment system, andthe surface having the other of the hook and loop attachment system, thefirst and second elements being attached to the surface by the hooks andloops, and the first and second elements being biased against oneanother.
 19. The decorative floor covering of claim 18, wherein at leastsome loops are approaching maximum extension and movement of at leastone of the elements away from the other is limited.
 20. (canceled) 21.(canceled)
 22. (canceled)
 23. (canceled)
 24. The decorative floorcovering of claim 23, wherein the predetermined amount is at leasttwenty-five percent of a maximum extension of the loops.
 25. Thedecorative floor covering of claim 1, wherein the first element isflexible and resists folding.
 26. (canceled)
 27. A method for making afloor covering module having a covering element with at least one sidesubstantially covered in one of hooks and loops of a hook and loopattachment system, and a sheet substantially covered the other of hooksand loops, the method comprising the steps of: (i) bending the sheet;(ii) placing the covering element onto the sheet to permit at least someof the hooks to engage at least some of the loops; and (iii) flatteningthe combined sheet and covering element for placement onto a surface.28. (canceled)
 29. (canceled)
 30. (canceled)
 31. (canceled) 32.(canceled)